IS 2039( Parts 1 vFc&m to 3):1991 Indian Standard STEEL TUBES FOR BICYCLE AND CYCLE RICKSHAWS- SPECIFICATION ( Second Revision ) First Reprint SEPTEMBER 1996 UDC 669'14 - 462 : 629'118'3 0 BIS 1991 BUREAU MANAK OF BHAVAN, INDIAN 9 BAHADUR STANDARDS SHAH ZAFAR 110002 Price Group 3 MARG NEW DELHI June 1991 Steel Tubes, Pipes and Fittings Sectional Committee, MTD 19 FOREWORD This Indian Standard ( Second Revision ) was adopted by the Bureau of Indian Standards, after the draft finalized by the Steel Tubes, Pipes and Fittings Sectional Committee had been approved by the Metallurgical Engineering Division Council. This Indian Standard was first published in 1964 and revised in 1981. The present revision covers requirements for electric resistance welded/induction welded tubes and cold finished electric resistance welded/induction welded tubes for the cycle and cycle rickshaw industries. Since seamless tubes are not used in the above industries, this specification does not cover the seamless tubes. While preparing revision of this standard, vast data collected from different precision tube manufacturers has been taken into consideration. cycle industries and To facilitate additions and alterations to the standard and to provide convenience to the users of the standard, this revision is being published in three separate parts but in the one volume as given below: Part 1 `Part 2 Part 3 General requirements Specific requirements Specific requirements welded steel tubes for electric resistance welded and induction welded steel tubes for cold finished electric resistance welded and induction For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rovded off in accordance with IS 2 : 1960 `Rules for rounding off numerical values ( revised )`. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. IS 2039 ( Part 1 ) : 1991 Indian Standard STEEL TUBES FOR BICYCLE AND CYCLE RICKSHAWS- SPECIFICATION PART 1 GENERAL REQUIREMENTS ( Second Revision ) I SCOPE 1.1 This Indian Standard provides for steel tubes for cycle and cycle rickshaw purposes in sizes up to and including 44'5 mm in outside diameter and covers the following types of tubes: Type of Steel Tubes Tube Designation Reference 5 CHEMICAL COMPOSITION Electric resistance welded and induction welded tubes Cold finished electric resistance welded and induction welded tubes 2 REFERENCES ERW Part II 5.1 The chemical composition of steel shall be as given in Table 1. The analysis of steel shall be carried out either by the method specifies in IS 228 and its relevant parts or by other established instrumental/chemical method. In case of dispute the procedure given in IS 228 and its relevant parts shall be the referee method. However, where the method is not given in IS 228 and its relevant parts, the refree method shall be as agreed between the purchaser and the manufacturer. Table 1 Tube Designation C Percent Max 0'15 ERW Cl ERW C2 0`20 0'25 lERW C3 CEW Part 111 Chemical Composition Si Percent Max 0'15 0'15 0'35 Mn Percent MUX P Percent MUX 2.1 The following Indian standards adjuncts to this standard: IS No. are ne$essary 0'60 0 90 1'20 0'06 0'05 OIOS S Percent Max O-06 0'05 0'05 Titk *Macro alloy may be present. 1387 : 1967 1894 : 1972 2328 : 1985 2335 : 1985 General requirements for the supply of metallurgical materials (first revision ) Method for tensile testing of steel tubes (first revision ) Method for flattening test on metallic tubes (jrst revision ) Method for drift expanding test on metallic tubes (first revision ) 6 WORKMANSHIP 6.1 The tubes shall have a workman like finish consistent with their method of manufacture and condition of supply. Small imperfections are permissible and it is permissible for these to be dressed out provided that the tubes thickness after dressing remains with in the tolerance limit. Peening of surface defects is not permitted. 6.2 Fin Height 3 MATERIAL 3.1 The general requirements relating to the supply of the material shall be as laid down in IS 1387 : 1967. 4 MANUFACTURE 4.1 The steel used for the manufacture of tubes shall be killed, semikilled or rimming quality. The tubes shall be manufactured by electric resistance or high frequency induction welded process, followed by subsequent cold working if required. 4.2 Condition of Supply The tubes may be supplied in either as welded or annealed/normalized condition. The external weld upset shall be removed completely i.e. flush with the outside surface of the tube. The internal fin height shall not exceed 60 percent of wall thickness. If a reduction in the internal fin height is required it shall be a subject of agreement between the manufacturer and the purchaser. 6.3 Straightness Unless otherwise agreed to between the purchaser and the manufacturer, tubes shall not be out of straightness by more than l/600 th of any cut length up to one metre. Tubes in longer length shall not depart from straightness by more than 1 in 250 of any length measured at tbe centre of that length. Tube ends shall be cut square with the axis of the tube and shall be free from accessible burrs. 1 IS 2039 ( Part 1 ) : 1991 7 INSPECTION 7.1 The purchaser or his representative shall have access at all reasonable times to those parts of the manufacturer's work engaged in the production and testing of the tubes that he has ordered. 8 MECHANICAL 8.1 Tensile Test Tensile test shall be carried out in accordance with IS 1894 : 1972 on one of the following at manufacturer's option: a) A length cut from the end of the selected tube (the ends being plugged for grips or flattened where necessary ); and b) A longitudinal strip cut from the tube and tested in the curved condition. The test piece\shall not include the weld. The tensile strength, the yield strength and the elongation shall be determined and the values shall be not less than those specified under the appropriate grade of the material. 8.2 Drift Expansion Test The test shall be carried out in accordance with IS 2335 : 1985. Pieces of suitable length cut from the tubes shall show no crack after being drifted to an included angle of 30" or 60", until the outside diameter is -increased by not less than the amount specified for an appropriate grade of material (see Tables 2 and 9 ). 8.3 Flattening Test Tube Designation ERWCI .ERWCZ ERW C3 l r = specified thickness. 9 DIMENSIONS AND TOLERANCES TESTS 9.1 The tubes covered in this standard have an outside diameter in the range of 6'35 to 44'5 mm and thickness in the range of 0'7 to 3'25 mm. The sizes other than those specified may be supplied as agreed to between the purchaser and the manufacturer. 9.2 Tolerances in the relevant on dimensions shall be as specified parts of this standard. Flattening Test Table 3 ( Clause 8.3 ) As Welded 3r+ 51' 8t* Subsequently Annealed or Normalized If* 2r* 3/* IO SELECTION OF TUBES FOR TESTING 10.1 Where the purchaser requires tests specially related to his order, the tests shall be carried out at the rate of one set of tests per batch of up to and including 1 500 m of one size of tube ordered, with an additional test for each additional 1 500 m or part thereof. When the purchaser requires additional tests related in his order, such tests shall be the subject of agreement between the purchaser and the manufacturer. 11 TEST CERTIFICATE AND MARKING Flattening test shall be mxde on lengths cut from the end of selected tubes in accordance with IS 2328 : 1985. The tubes shall show no crack after being flattened until the interior surfaces are at the middle, brought to such a position that the distance apart is not more than that specified for an appropriate grade of material (see Tables 3 and 9). In the case of electric resistance welded tubes, the tests shall be conducted on the tube with weld on top and weld on side. The burrs may be removed before testing. 8.3.1 Superficial surface ruptures, fissures noticed after flattening test shall be cause for rejection. Table 2 Drift Expansion Test ( Clause 8.2 ) As Welded Percent, l\fiIl 12 10 8 Subsequently .\nnealed or Normalized Percent, A4in 20 I5 10 11.1 The manufacturer shall carry out the specified tests applicable to each type of tube, and he shall supply a certificate stating that the tubes comply with the specified requirements. When the purchaser desires such certificates, this shall be stated in the enquiry and order. 11.2 Unless otherwise agreed to between the purchaser and the manufacturer, each bundle or crate or package of steel tubes shall be suitably marked with the following: a) Outside c) Method and diameter, thickness and length; Standard: ( ERW or CEW ); b) The number of this lndian of manufacture of the tube. d) Designation 11.2.1 Each bundle or crate or package may also be marked with the Standard Mark, details for which may be obtained from the Bureau of Indian Standards. 12 PROTECTION 12.1 Unless otherwise specified, the tubes shall be supplied with the manufacturer's mill protective coating. Special protection of the tubes for transit and storage shall be by agreement between the purchaser and the manufacturer. L Tube Designation ERW ERW Cl C2 ERW C3 IS 2039 ( Part 2 ) : lhl Indian Standard STEEL TUBES FOR BICYCLE AND CYCLE RICKSHAWS - SPECIFICATION PART 2 SPECIFIC REQUIREMENTS, AND INDUCTION WELDED ELECTRIC RESISTANCE STEEL TUBES ( ERW) WELDED ( Second Revision ) 1 SCOPE standard ( Part 2 ) covers the specific requirements for electric resistance welded and induction welded steel tubes ( ERW ) designated as ERW Cl, ERW C2 and ERW C3. 2 REQUIREMENTS 2.1 The general requirements shall conform those as g'lven in Part 1 of this standard. 3 MECHANICAL TESTS out as to 1.1 This 3.2.1 Tensile Properties The tensile Table 4. 3.2.2 properties shall be as specified in Drift Expunsion Test The percentage increase in outside diameter shall not be less than the values specified in Table 2. 3.2.3 Flattening Test The distance between internal surfaces shall not be greater than those specified in Table 3. 4 DIMENSIONS AND TOLERANCES 3.1 The mechanical tests shall be carried given in 8 of Part 1. 3.1.1 The number of mechanical in accordance with 10 of Part 1. tests shall be 4.1 The dimensions of tubes shall be in conformity with those given in 9 of Part 1. 4.2 Tolerances 3.2 Mechanical Properties The mechanical properties of test pieces selected and prepared in accordance with the requirements specified in Part 1, shall be as specified in Table 4. 4.2.1 Outside Diameter The tolerances on outside diameter ovality shall be as given in Table 5. including Table 4 Mechanical Properties ( Clauses 3.2 and 3.2.1 ) Tube Designation As Welded c-_--_-~----_-_-_? YS UTS MPa. MPa, Mitt Mh 200 300 350 300 400 430 Elongatioo Percent, Min 10 8 8 ERW Cl ERW C2 ERW C3 Annealed or Normalized p-------h-____ -YS UTS Elongation MPa, MPa, Percent, Min Min Min 170 270 27 220 360 25 260 380 23 1 MPa -- 1 Njmma = 0'102 0 kgf/mm'. Table 5 Outside Diameter h_----y c----Over Up to and Including mm mm 30 Tolerance on Outside Diameter ( ERW ) Tube ( Clause 4.2.1 ) As Welded D/t <40 and Annealed/Normalized D/r d 20 mm + 0'03 - 0'13 + 0'06 - 0'14 Annealed/Normalized Condition 20 < D/t < 40 mm 0.06 0'15 0'07 0'16 All Condition D/t > 40 I- 0'08 - 0'18 44'5 30 +0'1 - 0'2 NOTE - Due to the release O! internal stress when as welded tube is cut, a change in dimensions is usual Hence this tolerance does not mclude ovality within 100 mm of tube end which is in the as welded condition and which has a diameter to thickness ratio greater than 20 : 1. + + - 3 IS 2039 ( Part 2 ) : 1991 4.2.2 Tolerances on Thickness The tolerances on thickness including eccentricity but excluding the weld shall be f8 percent of the specified thickness. 4.2.3 Tolerances on Length The tubes shall be supplied in mill lengths of 4 to 7 m subject to a tolerance of -0 i-100 mm. The tolerance on specified cut leqthr given in Table 6. shall be as 500 Table 6 Tolerance on Specified Cut Lengths ( Clause 4.2.3 ) r---mm (AS 500 -0 +1 ;"B"; -0 +2 r----Over mm Length ---, upto and Including mm Tolerance h-.--T 2ooo 5ooo 7000 -0 +1*5 2ooo 5ooo In case of cut tubes at the end up to 100 mm the mean outside diameter ( Max ODi- Min OD 1 shall 2 be within these tolerances. -0 +3 -0 t-5 -0 +3 -0 +3 -0 +5 *Tolerance Icvcl A or B should be agreed upon mutually. 4 IS 2039 ( Part 3 ) : 1991 Indian Standard STEEL TUBES FOR BICYCLE AND CYCLE RICKSHAWS- SPECIFICATION PART 3 SPECIFIC AND REQUIREMENTS, COLD FINISHED RESISTANCE INDUCTION WELDED STEEL TUBES ( CEW ) WELDED ( Second Revision ) 1 SCOPE 1.1 This standard ( Part 3) covers the specific requirements for cold finished electric resistance welded and induction welded steel tubes ( CEW ) designated as CEW Cl, CEW C2 and CEW C3. 2 REQUIREMENTS 2.1 The general reauirements shall conform those give% in Part-1'of this Indian standard. 3 CHEMICAL COMPOSITION 4.2.1 Tensile Properties The tensile properties Table 7. shall be as specified in 4.2.2 Drift Expansion Test The nercentaae increased in outside dimensions shall `not be less than the values specified in Table 8. 42.3 Flattening Test to The distance between outside surfaces shall not be greater than those specified in Table 9. Table 8 Tube Designation CEW Cl CEW c2 CEW c3 3.1 The chemical composition of steel shall be as given in 5 and Table 1 of Part 1. 4 NUMBER OF MECHANICAL TESTS out as Drift Expanding Test ( Clause 4.2.2 ) Annealed/Normalized Tube, Min, Percent 20 15 IO 4.1 The mechanical per 8 of Part 1. tests shall be carried Table 9 4.1.1 The number of mechanical tests shall be in accordance with I0 of Part 1. Tube Designation Flattening Tests Annealed/Normalized Min t 2t 3r Tubes, ( Clause 4.2.3 ) 4.2 Mechanical Properties The mechanical properties of test pieces selected and prepared in accordance with the requirements specified in Part 1 shall be as specified in Table 7. f= CEW Cl CEW C2 CEW C3 thickness of tube. Table 7 Mechanical Properties ( Clatrses 4.2 and 4.2.1 ) Tube Designation As Drawn h------UTS MPa, Min 400 450 480 Annealed or Normalized ~_______~ F-------Crushing UTS YS MPa, MPa, ( %$;" ), Min Min 170 220 260 270 360 380 50 50 25 .-------YS MPa, Min 320 360 400 Crushing ( %;;d 25 25 L 1, CEW Cl CEW C2 CEW C3 I MPa - 0' 102 0 kgf/mm'. 5 IS 2039 ( Part 3 ) : 1991 5 DIMENSIONS AND TOLERANCES At no point the tolerance on thickness including eccentricity shall exceed f 7'5 percent of thickness. 5.2.3 Length The tube shall be supplied in either: a) random length of 3 to 7 m, or b) specified cut lengths to the tolerance in,Table 6. Table 10 including Over Up to and Including As Drawn D/t C 10 as Annealed/ Normalized D/t C 20 Condition mm $0'03 -0'13 +o.os -0'15 Normalized Condition 20 < D/t C 40 5.1 The dimensions of tube shall be in conformity with those given in 9 of Part 1. 5.2 Tolerances The tolerances on outside diameter, thickness and length shall be as follows. 5.2.1 Diameter The t,olerance on outside diameter ovality shall conform to Table 10. 5.2.2 Tolerance on Mean Thickness No given Tolerance Outside Diameter ( CEW ) ( Clause 5.2.1 ) tube shall have a mean thickness that departs from the specified thickness by more than: a) f0'1 mm for tubes up to and including 2'0 mm thick. 30 mm mm 30 44'4 +o.os -0'15 +o 08 -0'18 b) L-0.15 mm for tubes over 2 mm thick. 6 Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publication), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of `BIS Handbook' and `Standards Monthly Additions'. This Indian Standard has been developed from1 Dot : NO. MTD 19 ( 3339 1 Amendments Issued Since Publication Amend No. Date of Issue Text Affected BUREAU· Headquarters: FINDIAN STANDARDS Telegrams: Manaksanstha (Common to all offices) Telephone 323 76 17,323 38 41 86 99,337 85 9120 61 { 337 84 26,337 1 60 38 20 43 25 Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002 Telephones: 323 0131,323 83 75,323 94 02 Regional Offices: Central Eastern Northern Southern Western : Manak Bhavan, 9 Bahadur Shah Zafar Marg NEW DELHI 110002 l/14 C.I.T. Scheme VII M, V.I.P. Road, Maniktola CALCUTTA 700054 SC0 335336, Sector 34-A, CHANDIGARH 160022 C.I.T. Campus, IV Cross Road, MADRAS 600113 : : : 235 02 15 16,235 19,235 04 23 42 15 { 23.5 : Manakalaya, E9 MIDC, Marol, Andheri (East) MUMBAI 400093 832 92 95,832 78 58 832 78 91,832 78 92 Branches : AHMADABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE. FARIDABAD. GHAZIABAD. GLJWAHATI. HYDERABAD. JAIPUR. KANPUR. LUCKNOW. PATNA. THIRUVANANTHAPURAM. Reprography Unit, BIS, New Delhi, India NO. 1 DECEMBER 1995 TO IS 2039 ( Parts 1 to 3 ) : 1991 STEEL TUBES FOR BICYCLE AND CYCLE RICKSHAWS - SPECIFICATION (Second Revision) (Page 2, clause 8.2, last line) - Substitute the following for the existing: `( see Tables 2 and 8 ).' ( Puge 6, Table 10, co1 2 ) - Substitute `4~ for `44.4'. AMENDMENT (MTD19) Reprography Unit, BIS, New Delhi, India